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<p>Nickel-based superalloys are extensively employed in critical high-temperature aerospace applications owing to their exceptional high-temperature strength, oxidation resistance, and creep resistance. However, they are also regarded as typical difficult-to-machine materials. Abrasive waterjet (AWJ) milling, as a non-traditional machining technology, has been recognized as an effective solution for processing nickel-based superalloys, offering distinct advantages such as the absence of thermal damage, high material removal rates, and the capability to process difficult-to-machine materials. Since its introduction, AWJ milling has achieved substantial advancements in theory, practice, and numerical simulation. To support further research in this field, this study provides a systematic review and in-depth analysis of existing research on AWJ milling, with a particular focus on milling depth control, machined surface integrity, and finite-element-based investigations into AWJ milling mechanisms. These studies collectively offer essential theoretical foundations and technical guidance for future development. Finally, the current challenges associated with AWJ milling of nickel-based superalloys are summarized, and potential future research directions are proposed.</p>

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Towards high-performance abrasive waterjet milling of nickel-based superalloys: current progress, limitations and future research opportunities

  • 期刊论文

  • 发表日期：

    2026年3月18日

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  • Ruyi Zhao,
  • Dun Liu,
  • Weijie Zhang,
  • Hongtao Zhu,
  • Chuanzhen Huang,
  • Hankun Bao,
  • Jize Zhao,
  • Yue Dai,
  • Yifei Zhang

摘要

Nickel-based superalloys are extensively employed in critical high-temperature aerospace applications owing to their exceptional high-temperature strength, oxidation resistance, and creep resistance. However, they are also regarded as typical difficult-to-machine materials. Abrasive waterjet (AWJ) milling, as a non-traditional machining technology, has been recognized as an effective solution for processing nickel-based superalloys, offering distinct advantages such as the absence of thermal damage, high material removal rates, and the capability to process difficult-to-machine materials. Since its introduction, AWJ milling has achieved substantial advancements in theory, practice, and numerical simulation. To support further research in this field, this study provides a systematic review and in-depth analysis of existing research on AWJ milling, with a particular focus on milling depth control, machined surface integrity, and finite-element-based investigations into AWJ milling mechanisms. These studies collectively offer essential theoretical foundations and technical guidance for future development. Finally, the current challenges associated with AWJ milling of nickel-based superalloys are summarized, and potential future research directions are proposed.